Tile saw

ABSTRACT

A saw includes a base, a table supported above the base and configured to support a workpiece, an arm coupled to and extending above the base, and a saw unit supported by the arm so that the saw unit is disposed above the table. A first rail is fixedly coupled to the base and extends in a longitudinal direction, and a first bearing member is coupled to the table. The first bearing member moves along the first rail so that the table is moveable relative to the base in the longitudinal direction between a cantilevered position and an uncantilevered position, without any movement of the table relative to the first bearing member. The first bearing member is directly in contact with the first rail in both the cantilevered and uncantilevered positions.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.11/017,992, filed Dec. 21, 2004, titled “Tile Saw,” now U.S. Pat. No.7,387,120, which is a continuation of U.S. patent application Ser. No.10/140,668, filed May 8, 2002, titled “Tile Saw, now U.S. Pat. No.6,845,768, which is a continuation of U.S. patent application Ser. No.09/413,769, filed Oct. 7, 1999, titled “Tile Saw,” now U.S. Pat. No.6,427,677, which claims priority under 35 U.S.C. § 119(e) to U.S.Provisional Application No. 60/106,568, filed Nov. 2, 1998, titled “TileSaw,” each of which is incorporated herein by reference.

TECHNICAL FIELD

This application relates generally to tile or masonry saws and, moreparticularly, to tile saws with expanded capacity.

BACKGROUND

A typical tile saw includes a base which supports a generally flat tabletop. A saw unit may be disposed on the base or table for cutting aworkpiece, such as a tile or masonry brick, disposed on the table.However, the maximum cutting capacity of such tile saws is limited bythe size of the machine, i.e., the envelope.

Accordingly, persons skilled in the art have devised a tile saw wherethe base has two tracks and the table has bearings or wheels riding onthe tracks, so that the table can be slid relative to the saw unit forincreased capacity. Such tile saws, however, are usually susceptible todust collecting between the tracks and wheels, which creates bindingbetween the base and the table. Ultimately, the binding may causeuneven, inaccurate cuts, which may translate into loss of time,materials and/or profit for the user.

Further, the capacity of such tile saws is usually limited to the lengthof the tracks. In other words, if a user wants increased capacity, hemay have to lengthen the tracks. However, longer tracks may result inless portability of the tile saw.

It is an object of this invention to provide a saw with increasedcutting capacity without sacrificing portability.

SUMMARY

In an aspect, a tile saw comprises a base, a table disposed on the base,a saw unit disposed on the base, a first stationary rail having a firstlength extending generally along a first direction, the first stationaryrail being connected to one of the table and saw unit, and a firstmovable rail engaging the first stationary rail and extending generallyparallel to the first stationary rail, the first movable rail beingconnected to the other of the table and saw unit, wherein the firstmovable rail is movable with respect to the first stationary rail suchthat the other of the table and saw unit is movable generally along thefirst direction over a range which exceeds the first length. The firstmovable rail may be slidingly received over the first stationary rail.

Additional features and benefits of the present invention will beapparent from the accompanying drawings, the detailed description below,and the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective side view of a first embodiment of a tile sawaccording to the present invention;

FIG. 2 is a plan view, partially in cross section, of the tile sawillustrated in FIG. 1;

FIG. 3 is a perspective view showing an embodiment of a telescoping rackand pinion assembly according to the present invention;

FIG. 4 is a side elevation view, partially in cross-section, along planeIV-IV of FIG. 1;

FIGS. 5A and 5B are schematic illustrations of the telescoping fenceassembly according to the present invention;

FIGS. 6A and 6B are enlarged perspective views illustrating the bumpsschematically shown in FIGS. 5A and 5B;

FIG. 7 is a perspective side view of a second embodiment of a tile sawaccording to the present invention;

FIG. 8 is a side elevation view of the knob drive assembly of the secondembodiment;

FIG. 9 is a perspective side view of a third embodiment of a tile sawaccording to the present invention;

FIG. 10 is a perspective side view of a fourth embodiment of a tile sawaccording to the present invention; and

FIG. 11 is a perspective side view of a fifth embodiment of a tile sawaccording to the present invention

DETAILED DESCRIPTION

The invention is now described with reference to the accompanyingfigures, wherein like numerals designate like parts. FIG. 1 illustratesa first embodiment of the present invention, where tile saw 10 comprisesa base 11 which supports a generally rectangular work table 12. Slidablerelative to table 12 is saw unit 13, which comprises a blade 14 and amotor 15 driving the blade 14. The saw unit 13 is slidably disposed onguide rods 16, so that the saw unit 13 can be positioned at any positionalong rods 16. Persons skilled in the art will recognize that one guiderod 16 may be used, but it is possible to use at least two rods 16 inorder to increase stability.

Further, saw unit 13 can be adapted to bevel, i.e., change the angle ofblade 14 relative to the table 12, as is known in the art.

Saw unit 13 also has a water conduit 8 for lubricating and cooling theblade 14, as is known in the art. Water sent through conduit 8 willdrain into base 11 through table 12 and may be re-pumped through conduit8 as is known in the art.

The saw unit 13 is adapted so that a drill press 30 can be attachedthereto. By changing the relative position of saw unit 13 and/or table12, the drill press 30 can be positioned over a tile workpiece formaking round or arcuate cuts. Accordingly, the drill press 30 may beprovided with an annular or circular cutting tool, e.g., made ofdiamond.

Rail assemblies 100 are used to provide slidable movement between thesaw unit 13 and table 12. Persons skilled in the art are directed toU.S. Pat. No. 5,722,308, assigned to the present assignee, for furtherinformation on the rail assemblies 100 and their operation. Further,U.S. Pat. No. 5,722,308 is hereby incorporated by reference into thepresent specification.

Rail assemblies 100 are each comprised of an inner rail 18 and an outerrail 19. Inner rails 18 are disposed on the front and rear of table 12.In one implementation, the inner rails 18 have a generally C-shapedcross-section and a length generally equal to the width of table 12.Inner rails 18 are fixedly secured to table 12 using a plurality offasteners 101 which are spaced along the entire length of inner rail 18.As shown in FIG. 4, fasteners 101 include a bolt 102, a nut 103 and abushing 122. Bolt 102 extends through inner rail 110 and through abracket 124 which is secured to or is an integral part of table 12.Bushing 122 is made from UHMW-PE or low friction polymeric material andis located between inner rail 18 and bracket 124 with the assembly beingsecured by nut 103. Bushing 122 may extend over the entire length ofinner rail 18.

A glide strip 18C may be disposed on or wrapped around inner rail 18 tofacilitate the movement of outer rail 19 with respect to inner rail 18.In an embodiment, glide strip 18C is made of UHMW polyethylene or anylon based material injection molded over inner rail 18. Glide strip18C extends over the entire length of inner rail 18.

Outer rails 19 are generally C-shaped members slidingly received overthe inner rails 18. Outer rails 19 are made of steel and roll-formedinto the desired shape. A rail mechanism 200 allows a user to move theouter rails 19 relative to the inner rails 18, as explained below.

Carriages 17 supporting guide rods 16 and saw unit 13 are fixedlydisposed on the outer rails 19. Persons skilled in the art willrecognize that the tile saw 10 may be designed so that only one carriagesupports the guide rods 16 and saw unit 13.

By providing outer rails 19 which telescope with inner rails 18, the sawunit 13 is deployable beyond the envelope of work table 12 in order toprovide additional cutting capacity, as shown in FIG. 1, yet maintaininga compact envelope for simplifying transportation of tile saw 10. Thecompact envelope of tile saw 10 facilitates both storage of tile saw 10and the movement of tile saw 10 from one job site to the another.

Persons skilled in the art will recognize that, to perform the cut, theoperator need only push saw unit 13 towards the workpiece. The rigidconnection between the outer rails 19, the carriages 17 and the rails 16will maintain the outer rails 19 moving together the same distance.Persons skilled in the art will recognize that other means to obtain thesame result exist.

For example, outer rails 19 may comprise a rack 376 which can beintegral with outer rail 19 or it can be a separate component attachedto a lower extending flange of outer rail 19 by a plurality of screws.Rack 376 extends over the entire length of outer rail 19. Rack 376includes a plurality of rack teeth 378 which may extend over the entiresurface of the rack. An enlarged tooth may be provided at the end ofeach rack 376 to limit the travel of outer rail 19 with respect to innerrail 18 in either direction, as disclosed in U.S. Pat. No. 5,722,308,which is again hereby incorporated by reference.

Rail mechanism 200 comprises a pinion shaft 150, a pair of pinion gears340 and an adjustment wheel 154. Pinion gears 340 and adjustment wheel154 are fixedly secured to pinion shaft 150 for rotation therewith.Pinion shaft 150 is rotatably secured to base 11 (e.g., by bearingmounts 346) such that pinion gears 340 are engaged with rack teeth 378on each outer rail 19 with adjustment wheel 154 extending beyond thefront outer rail 19 for accessibility by an individual. Thus, rotationof adjustment wheel 154 cause rotation of pinion shaft 150 and piniongears 340 which, due to their engagement with rack teeth 378 of rack376, cause longitudinal movement of each outer rail 19 with respect toeach inner rail 18 and the movement of saw unit 13 relative to saw table12.

Due to the fact that both front and rear pinion gears 340 rotatesimultaneously and by the same amount due to their rotation with pinionshaft 150, both outer rails 19 will move together and the same distancedue to the engagement of rack teeth 378 of each rack 376 with arespective pinion gear 340. This simultaneous and equal movement of eachouter rail 19 will thus ensure that the relationship between saw unit 13and table 12 will be maintained during the movement of the saw unit 13.

Accordingly, the present invention allows the saw unit 13 to be movedover a range of lengths which exceeds the length of the stationary innerrails 18. The saw unit 13 can be moved beyond the width of the worktable 12, outwardly of either side edge, without requiring that thestationary rails have a length which is greater than the width of thetable to provide for such movement.

The telescoping rails of the present invention have sufficient clearancebetween each inner rail and outer rail disposed thereon to accommodatethe non-straightness of the rails. This clearance can cause excessiveend play of the outer rail as it moves toward its totally extendedposition. Thus, it may be desirable, in the present invention, toprovide a system for stabilizing the outer rail as it moves to it fullyextended position.

Accordingly, FIGS. 5A and 5B schematically represent an inner rail. 18and an outer rail 19. As before, inner rail 18 is adapted to be securedto work table 12. Outer rail 19 telescopically engages inner rail 18 asshown previously with sufficient clearance maintained between the innerand outer rails to accommodate any non-straightness. Each end of innerrail 18 would include an outwardly extending bump 504 and each end ofouter rail 19 would include an inwardly extending bump 506. Bumps 504contact the inner surface of outer rail 19 while bumps 506 contact theouter surface of inner rail 18. These contact points help stabilize themovable rail against vertical movement in any extended position of themovable rails. However, bumps 504 and 506 must be provided in a mannerwhich allows for outer rail 19 to move from the position shown in FIG.5A to that shown in 5B. That is, it is necessary for inwardly extendingbumps 506 to pass through outwardly extending bumps 504.

FIG. 6A illustrates a construction of inner rail 18 and outer rail 19which provides bumps 504 and 506 which pass through each other. Asexplained above, guide strip 18C may be injection molded over inner rail18 as shown. Glide strip 18C may be molded so as define a pair of pads508 on the upper and lower surfaces of inner rail 18 at each end. Eachpair of pads 508 defines a channel 510 extending longitudinally alongthe length of inner rail 18 for a short distance. The pair of pads 508are designed such that they slidingly engage the interior surfaces ofouter rail 19 to reduce or eliminate the clearances between the tworails. Pads 508 also could be a separate component assembled to innerrail 18.

FIG. 6B illustrates outer rail 19 incorporating inwardly extending pads512 integrally formed as a part of outer rail 19 at each end. One pad512 is formed into an upper wall of outer rail 19 while the second pad512 is formed into the lower wall of outer rail 19. Pads 512 may beformed by stamping the rails inwardly in the roll forming process of therails. Pads 512 are positioned to align with channels 510 defined bypads 508 such that outer rail 19 is allowed to move outwardly beyondinner rail 18 in both directions as is schematically illustrated inFIGS. 5A and 5B. Pads 508 function as bumps 504 and pads 512 function asbumps 506 as described with reference to FIGS. 5A and 5B. Thus, thecontact of pads 508 and 512 with outer rail 19 and inner rail 18,respectively, stabilizes the outer rails in the extended position.Persons skilled in the art are directed to U.S. Pat. No. 5,722,308, forother means for providing bumps 504 and 506.

Furthermore, persons skilled in the art are directed to U.S. Pat. No.5,722,308, for further means for moving the outer rails 19 in relationto the inner rails 18.

FIG. 7 illustrates a second embodiment of the tile saw according to thepresent invention, where like numerals refer to like parts. Thisembodiment operates in a similar manner to the first embodiment. Themain differences between this embodiment and the previous one is that:(1) inner rails 18 may be attached on the same side of base 11; (2)carriage 17 may be connected to both outer rails 19; and/or (3) rods 16may be cantilevered. A first inner rail 18 is disposed above a secondinner rail 18 in a parallel manner. Also at least one of rods 16 mayhave a stop 16S to prevent saw unit 13 from being removed off rods 16.Having such construction allows the user to cut a workpiece W having awidth greater than the width of table 12 and/or base 11.

In order to move the outer rails 19, the operator need only push on sawunit 13. Alternatively, a knob assembly 400 may be provided in base 11.Knob 154 is connected to a pinion 410, which meshes with two pinions411. Pinions 411 have the same diameter and/or distance between teeth.Pinions 411 then mesh with the corresponding outer rails 19.Accordingly, when user rotates knob 154, pinions 410 and 411 rotate,moving outer rails 19 in the same direction and speed.

FIG. 9 illustrates a third embodiment of the tile saw according to thepresent invention, where like numerals refer to like parts. Thisembodiment operates in a similar manner to the previous embodiments. Themain difference between this embodiment with the first embodiment isthat the table 12 is fixedly attached to the outer rails 19, so that thetable 12 can be moved relative to saw unit 13 and base 11. Accordingly,carriages 17 are fixedly connected to base 11. In addition, a sheet maybe attached to table 12, so that water from table 12 is collected on thesheet and drained into base 11. The sheet may be pliable so that it canfollow table 12 through the entire range of motion. As mentioned above,the user need only push the table 12 13 to cut the workpiece.Alternatively, the user may turn knob 154, thus rotating pinion shaft150 and forcing outer rails 19 (and thus table 12) to move.

FIG. 10 illustrates a fourth embodiment of the tile saw according to thepresent invention, where like numerals refer to like parts. Thisembodiment operates in a similar manner to the previous embodiments. Themain differences between this embodiment and the third embodiment isthat: (1) inner rails 18 may be attached on the same side of base 11;and/or (2) rods 16 may be cantilevered. A first inner rail 18 isdisposed above a second inner rail 18 in a parallel manner. Also atleast one of rods 16 may have a stop 16S to prevent saw unit 13 frombeing removed off rods 16. Having such construction allows the user tocut a workpiece W having a width greater than the width of table 12and/or base 11.

In an example, the lower outer rail 19 supports the table 12 via a beam19B.

In order to move the outer rails 19, the user need only push table 12.Alternative, a knob assembly similar to knob assembly 400 may beprovided in base 11. Accordingly, when user rotates knob 154, pinions410 and 411 rotate, moving outer rails 19 in the same direction andspeed.

FIG. 11 illustrates a fifth embodiment of the tile saw according to thepresent invention, where like numerals refer to like parts. Thisembodiment operates in a similar manner to the first and thirdembodiments. The main differences between this embodiment and the thirdembodiment is that: (1) saw unit 13 is disposed below table 12; and/or(2) table 12 is split in order to allow blade 14 to extend therethroughthroughout the range of movement of table 12.

Saw unit 13 may have a riving knife 13K connected thereto so that thecut pieces of workpiece W do not contact each other. The use andinstallation of riving knife 13K is well known in the art.

Water conduit 8 (not shown) may be disposed below table 12 forlubricating and cooling the blade 13, as is known in the art.

Numerous modifications may be made to the exemplary implementationsdescribed above. These and other implementations are within the scope ofthe following claims.

1. A saw comprising: a base; a table supported above the base andconfigured to support a workpiece; an arm coupled to and extending abovethe base; a saw unit supported by the arm so that the saw unit isdisposed above the table; a first rail fixedly coupled to an inner sidesurface of the base and extending in a longitudinal direction; and afirst bearing member coupled to the table, wherein the first bearingmember moves along the first rail so that the table is moveable relativeto the base in the longitudinal direction between a cantileveredposition and an uncantilevered position, without any movement of thetable relative to the first bearing member between a minimum and maximumlongitudinal range of movement of the table, the first bearing memberdirectly in contact with the first rail in both the cantilevered anduncantilevered positions.
 2. The saw of claim 1, wherein the firstbearing member comprises a movable rail engaging the first rail andextending generally parallel to the first rail.
 3. The saw of claim 2,wherein the movable rail is slidingly received over the first rail. 4.The saw of claim 1, further comprising: a second rail fixedly coupled tothe base and extending in the longitudinal direction substantiallyparallel to the first rail; and a second bearing member coupled to thetable, the second bearing member moving along the second rail when thetable is moved in the longitudinal direction without any movement of thetable relative to the second bearing member.
 5. The saw of claim 4,wherein the second bearing member is directly in contact with the secondrail in both the cantilevered and uneantilevered positions.
 6. The sawof claim 1, wherein the arm is positioned so that the saw unit iscantilevered over the table.
 7. A tile saw configured to cut comprising:a generally rectangular base; a first stationary rail and a secondstationary rail, each fixedly coupled to the base and extending in alongitudinal direction generally parallel to one another; a table havinga top surface for supporting a worldpiece, and a first bearing memberand a second bearing member coupled to outer side surfaces of the table,the first bearing member configured to move along the first stationaryrail and the second bearing member configured to move along the secondstationary rail so that the table is moveable relative to the base inthe longitudinal direction; an arm coupled to and extending upward fromthe base; and a saw unit supported by the arm so that the saw unit iscantilevered above the table, the saw unit having a motor housingcontaining a motor and configured to receive a cutting wheel for beingdriven by the motor, wherein the first bearing member moves along thefirst stationary rail and the second bearing member moves along thesecond stationary rail so that the table is moveable relative to thebase in the longitudinal direction between a cantilevered position andan uncantilevered position, without any movement of the table relativeto the first and second bearing members, at least one of the firstbearing member and the second bearing member remaining directly incontact with at least one of the first stationary rail and the secondstationary rail in both the cantilevered and uncantilevered positions.8. The tile saw of claim 7, wherein the first bearing member remainsdirectly in contact with the first stationary rail and the secondbearing member remains directly in contact with the second stationaryrail in both the cantilevered and uncantilevered positions.
 9. The tilesaw of claim 7, further comprising a fluid conduit configured tolubricate a cuffing wheel received on the motor housing.
 10. The tilesaw of claim 7, further comprising the cuffing wheel.
 11. The tile sawof claim 7, wherein the saw unit is configured to bevel.
 12. The tilesaw of claim 7, wherein at least one of the first stationary rail andthe second stationary rail comprises a C-shaped cross-section.
 13. Thetile saw of claim 7, wherein at least one of the first stationary railand the second stationary rail comprises a glide strip.
 14. The tile sawof claim 13, wherein the glide strip comprises at least one of UHMWpolyethylene and a nylon based material.